Method for removing a twist-module sub-assembly in a knotter assembly

ABSTRACT

The subject invention relates to a knotter assembly for use in a wire-tieing system, and method for removing and replacing a twist-module sub-assembly in a knotter assembly on a material baling apparatus. Embodiments of the knotter assembly include a slidably removable twist module assembly, a ratcheted cover arm assembly, and a torque tube assembly having two operating arms that carry all of the operating components for actuating various elements of the knotter assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S.application Ser. No. 14/263,483, filed Apr. 28, 2014, entitled “Methodof Removing a Twist-Module Sub-Assembly in a Knotter Assembly,” havingAttorney Docket No. LGPL.203189, now U.S. Pat. No. ______ issued ______,2015, which is a continuation of U.S. application Ser. No. 13/753,188,filed Jan. 29, 2013, entitled “Method for Removing a Twist-ModuleSub-Assembly in a Knotter Assembly,” having Attorney Docket No.LGPL.180975, now U.S. Pat. No. 8,757,055, issued Jun. 24, 2014, which isa divisional of and claims priority to U.S. application Ser. No.12/717,616, filed Mar. 4, 2010, entitled “Knotter Assembly,” havingAttorney Docket No. LGPL.154618, now U.S. Pat. No. 8,397,632, issuedMar. 19, 2013, the entire contents of each of which is herebyincorporated by reference.

BACKGROUND

Various types of bulk materials are shipped, stored, and otherwiseprocessed and distributed in the form of bales. For example, recyclablematerials, such as paper, plastic and metal are formed into bales foreasier handling. Bulk material such as cotton might also be processedinto compressed bales. Formed bales are easier and more efficient tohandle than loose bulk material. Furthermore, bales are more organizedand take up less storage or shipping space than loose material.

In a baling process, the loose material is collected and formed into abale. After the bales of material are formed into the proper shape, theyare usually wrapped or otherwise fitted with a structure which will keepthem in the desired bale shape. For example, it is generally known towrap bales of compressible material with wire or some other elongatedbinding device to keep the bales in their form for shipping and storage.Wire is preferable because of its strength, low cost, and the ease withwhich it is handled.

One method of forming a bale directs the compressible material into anautomatic baler where it is pressed into a bale by a ram and then movedby the ram through the baler. At a certain position along the balingpath, the bale is tied or bound together with wire. More specifically, atieing system is used with the baler and guides a continuous wire strandaround the bale through a wire-guide track to surround the bale as itprogresses through the baler. The wire is overlapped when it completelysurrounds the bale. The tieing system engages the bale and theoverlapped wire and ties the wire around the bale.

Pneumatic, hydraulic, or electric wire-tieing machines having means forgripping and twisting two wires, or opposite ends of the same wire,together are well-known. In these and similar systems, a knotterassembly associated with the tieing system engages the overlapped wireand twists together the overlapped ends of the wire strands to securethe wire in place around the bale. The knotter assembly utilizes aslotted wire-twister pinion having a central pinion gear. Separatebearing elements and bushings are mounted for supporting and protectingthe gear, and wire guides, wire-guide blocks, fingers, cutters, andother parts must be separately installed for knotting and cutting thewire. Such parts are subject to wear and breakage and must be replacedfrom time to time.

In addition, different sizes of these parts may be required forprocessing wires of different gauge, so that, again, the parts must bechanged. Such changes of parts may require considerable down timewhereby the efficiency in the overall wire-tieing operation is reduced.As a result, baling facilities often use the heaviest wire that will beneeded for a given manufacturing period on all applications, regardlessof whether the application could be done with a lighter wire. Thus, thelack of the ability, in conventional knotter assemblies, to quicklychange out the parts discussed above leads to inefficiencies, high wirecosts, and the like.

SUMMARY

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the detaileddescription. This summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

A wire tieing system in accordance with the principles of the presentinvention is utilized to wrap and tie a bale of material with wire. Thesystem comprises a wire guide for guiding the wire around a bale ofmaterial and a knotter assembly configured for receiving portions ofwire in the guide and securing the portions together to tie the wire,and therefore, tie a bale of material. Generally the knotter assembly ismounted at the top or proximate the wire guide. The apparatus is usedwith a baling device of suitable construction.

Embodiments of the present invention relate to a knotter assembly foruse in a wire-tieing system on a baler. In embodiments, the assemblyincludes a base plate; a pair of parallel opposed side walls; and a setof spacers for supporting a torque tube assembly disposed between theside walls, wherein the torque tube assembly includes a torque tube anda pair of operator members fixably attached to the torque tube, whereina first operator member includes components for actuating a cutterassembly and a first cover arm, the first cover arm being coupled with aknotter cover. According to some embodiments, the second operator memberincludes components for actuating a gripper assembly and a second coverarm, the second cover arm being coupled with the knotter cover. Inembodiments, a roller cam is rotatably coupled between the two operatormembers and engages a drive slot in a segment gear such that actuationof the operator members causes the roller cam to drive the segment gear,which, in turn, drives a twister pinion.

Various embodiments of the inventions include a wire-tieing machine fortwisting or tieing together end portions of wires. In embodiments, themachine includes a frame assembly, wherein the frame assembly includes abase plate and a pair of parallel opposed side walls, and wherein afirst mounting block and a first twist-module guide rail is attached toan inside surface of a first side wall, and further wherein a secondmounting block and a second twist-module guide rail is attached to aninside surface of a second side wall. According to an embodiment, themachine also includes a knotter cover arm assembly, wherein the knottercover arm assembly includes a pair of opposed knotter cover armscoupled, at a lower end of each arm, to a knotter cover, and pivotablycoupled, at an upper end of each arm, to a shaft such that rotation ofthe arms causes the knotter cover to lift away from the wire-tieingmachine. In embodiments, the machine also includes a twist moduleassembly, wherein the twist module assembly includes a main block thathouses a twister pinion having a pinion gear, and wherein the twistmodule assembly is removably coupled to the frame assembly by way of apair of slots that fit over the respective twist module guide rails.

Embodiments of the inventions include a wire-tieing machine for twistingor tieing together end portions of wires that includes a frame assembly,wherein the frame assembly includes a base plate and a pair of parallelopposed side walls; a knotter cover arm assembly, wherein the knottercover arm assembly includes a pair of opposed knotter cover armscoupled, at a lower end of each arm, to a knotter cover, and pivotablycoupled, at an upper end of each arm, to a shaft such that rotation ofthe arms causes the knotter cover to lift away from the wire-tieingmachine, and further wherein the knotter cover arm assembly includes aratchet assembly for locking the knotter cover in a lifted-awayposition; and a twist module assembly, wherein the twist module assemblyincludes a main block that houses a twister pinion having a pinion gear.

These and other aspects of the invention will become apparent to one ofordinary skill in the art upon a reading of the following description,drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in detail below with reference to theattached drawing figures, wherein:

FIG. 1 depicts a perspective view of a two-ram baler with a wire-tieingdevice in accordance with embodiments of the present invention;

FIGS. 2A and 2B depict perspective views of a knotter assembly inaccordance with embodiments of the present invention;

FIG. 3 depicts another perspective view of a knotter assembly, with aside wall cut away, in accordance with embodiments of the presentinvention;

FIG. 4 depicts a perspective view of a frame assembly in accordance withembodiments of the present invention;

FIG. 5 depicts another perspective view of a frame assembly inaccordance with embodiments of the present invention;

FIG. 6 depicts a perspective view of a frame assembly and a twist moduleassembly in accordance with embodiments of the present invention;

FIG. 7 depicts another perspective view of a frame assembly and a twistmodule assembly in accordance with embodiments of the present invention;

FIG. 8 depicts an exploded perspective view of a twist module assemblyin accordance with embodiments of the invention;

FIG. 9 depicts a partially cut-away perspective view of a knotterassembly in accordance with embodiments of the invention;

FIG. 10 depicts a side view, with a side wall removed, of a knotterassembly in accordance with embodiments of the invention;

FIG. 11 depicts a perspective view of a torque tube assembly inaccordance with embodiments of the invention;

FIG. 12 depicts a perspective view of a gripper assembly in accordancewith embodiments of the invention;

FIG. 13 depicts a top-plan view of a gripper assembly in accordance withembodiments of the invention;

FIG. 14 depicts a perspective view of a cover plate, showingwire-guiding and twisting components in accordance with embodiments ofthe invention;

FIG. 15 depicts a perspective view of a twist module assembly, showingwire-guiding and twisting components in accordance with embodiments ofthe invention;

FIG. 16 depicts a perspective view of the mated wire-guiding andtwisting components of a cover plate and a twist module assembly inaccordance with embodiments of the invention;

FIG. 17 depicts a perspective view of a ratchet assembly in accordancewith embodiments of the invention;

FIG. 18 depicts another perspective view of a ratchet assembly inaccordance with embodiments of the invention; and

FIG. 19 depicts a perspective view of a knotter assembly with a coverassembly in an open position in accordance with embodiments of theinvention.

DETAILED DESCRIPTION

Turning now to the drawings, which are not represented in scale, butrather to clearly show the various embodiments and constructions, FIG. 1depicts a front perspective view of an exemplary baling machine 10 inaccordance with embodiments of the inventions. The baling machine 10 canbe a horizontal baler, a vertical baler, a two-ram baler, or any othertype of machine used for baling materials. The illustrated balingmachine 10 is a two-ram horizontal baler and includes an inlet hopper11, a first ram 12 for compressing the material, a second ram 13 forejecting the baled material, a bale outlet 14 and a wire-tieing system15 disposed around the bale outlet 14. The baling machine 10 can includeany number of other assemblies, as well.

As shown in FIG. 1, the wire-tieing system 15 includes a pinch-rollmechanism 16, a knotter assembly 17, and a spring-loaded, separable wireguide track 18 disposed around the bale outlet 14. The pinch-rollmechanism 16 pulls wire 19 from a spool 20. In embodiments, a feed andtensioning structure 21 can be used to ensure that the wire is properlyfed around the track 18 under sufficient tension to be engaged by theknotter assembly 17.

In operation, the wire 19 is directed around the track 18, whichincludes a groove (not shown) such that the leading end of the wire 19overtakes the trailing end. A bale of material (not shown) is directedinto the bale outlet 14, which is encircled by the track 18. The wire 19encircling the bale is engaged by the knotter assembly 17, which cutsthe trailing wire and engages the ends of wires to twist the ends of thewires together for tieing, and for securing the wire around the bale.The system 15 will generally be utilized with a baling structure orbaler, and the bale of material is pushed through the outlet 14 by thebaler. Exemplary wire-tieing systems of the type depicted in FIG. 1include the Model 330 and Model 340 Tieing Systems available from L & PWire-Tie Systems, a Division of Leggett Platt, Incorporated of Carthage,Mo.

Turning now to FIGS. 2A, 2B, and 3, perspective views of the knotterassembly 17 are depicted in accordance with embodiments of theinventions. The knotter assembly 17 broadly includes a frame assembly22, a twist module assembly 23, a segment gear assembly 24, a knotterarm assembly 25, a ratchet assembly 26, a gripper assembly 27, a torquetube assembly 28, and a cylinder assembly 29. In embodiments, theknotter assembly 17 can include other assemblies and parts notillustrated herein.

As best seen in FIGS. 4 and 5, the frame assembly 22 includes twoparallel opposed frame walls: a cutter-side frame wall 30 and agripper-side frame wall 31. A top brace 32 extends between the tops ofthe frame walls 30, 31 near the front of the frame assembly 22. Two backbraces 33, 34 extend between the two frame walls 30, 31 across the backside of the frame assembly 22. Additionally, the frame assembly 22includes a base plate 35 and a cylinder mount 36.

The cutter-side frame wall 30 includes an aperture 38 and spacer plug 43for pivotably coupling one end of a torque tube 128 to the frameassembly 22. Similarly, the gripper-side frame wall 31 includes anaperture 39 and spacer plug 43 for pivotably coupling the other end ofthe torque tube 128 to the frame assembly 22. Spacer plugs 44, 46 areprovided for pivotable attachment of a segment gear bearing housing 210to the frame assembly 22.

An open slot 40 extends from the front of the cutter-side frame wall 30to allow for travel of a cutter-lever cam assembly 79. As is furtherillustrated, two notches 41, 42 are provided in the lower-front portionof the frame walls 30, 31, respectively, for allowing removableattachment of the twist module assembly 23 to module mount blocks 47, 48along twist module guide rails 49, 50.

Turning now to FIGS. 6 and 7, a front perspective view of the frameassembly 22 and the twist module assembly 23 is shown in accordance withembodiments of the inventions. As illustrated and explained furtherbelow, the twist module assembly 23 is configured to be removablycoupled to the frame assembly 22. The twist module assembly 23 includesa modular housing 52 that is slidably removable from the frame assembly22. A cutter assembly 51 is attached at a first end of the modularhousing 52 (i.e., the cutting side).

As shown in FIGS. 8-9, the modular housing 52 includes a recess 53 inwhich a twister pinion 54 is disposed. The modular housing 52 furtherincludes an ejector slot 55 disposed on each side of the recess 53 andoriented parallel to the recess 53. As is further shown in FIGS. 6 and8, the modular housing 52 includes two opposed mounting channels 56, 57.Each mounting channel 56, 57 is a void defined by a top surface 58 ofthe modular housing 52 (forming the bottom of the channel), and at leastone surface of a module-mounting member 59, 60. Each module-mountingmember 59,60 is, in embodiments, L-shaped and includes a first portion61,63 extending vertically from the upper surface 58 of the modularhousing 52 and a second portion 62,64 extending laterally away from thefirst portion 61,63 forming channels 56,57, defined by the void betweenthe upper surface 58 of the modular housing 52, the outside surface 65of the first portion 61,63 of the module-mounting member 59,60 and thelower surface 66 of the second portion 62,64 of the module-mountingmember 59,60. According to various embodiments of the inventions, themodule-mounting members 59, 60 can be other shapes, as well, so long asthe channels 56, 57 formed thereby mate with guide rails 49, 50.

The modular housing 52 is coupled to the frame assembly 22 by slidingthe modular housing 52 onto the frame assembly 22. This slidablecoupling is achieved by aligning each of the mounting channels 56, 57with a corresponding guide rail 49, 50 and sliding the module-mountingmembers 59,60 onto the respective guide rails 49, 50 such that the guiderails 49,50 occupy the channels 56, 57. The modular housing 52 istemporarily secured into place with two connectors 67, 68 such as, forexample, bolts or other coupling devices, which are inserted into bores69, 70 and pass into threaded bores 71, 72 of mounting blocks 47, 48. Inthis manner, the modular housing 52 (and thus, the twist module assembly23) can be easily removed and replaced by removing the two connectors67, 68 and sliding the modular housing 52 off of the guide rails 49.

With particular reference to FIGS. 8 and 15, the twist module assembly23 further includes wire guides 73, 74 forming wire paths 238 and 235, agripper side yolk 95, wire guide blocks 231, 232 forming wire paths 236and 237, a twister pinion 54, and two pinion bushings 75, 76. Thesecomponents 54, 73, 74, 75, 76, 231, and 232 are known in the art and onehaving skill in the art will readily appreciate that components such asthe components 54, 73, 74, 75, 76, 231, and 232 generally aregauge-specific and subject to wear from normal operation. Inconventional knotter assemblies, each of these components 54, 73, 74,75, 76, 231, and 232 (and, in some cases, additional components) isconfigured for a particular size (e.g., gauge) of wire. Therefore, inorder to change the size of wire being used with conventional balers,each of these components 54, 73, 74, 75, 76, 231, and 232 had to beremoved and replaced with similar components manufactured for thedesired wire gauge. Moreover, these components tend to wear quickly. Tobetter address these issues, the twist module assembly 23 can be quicklyremoved from the frame assembly 22 in embodiments of the presentinvention, and replaced with a new twist module assembly 23 havingappropriately sized components, or having new or repaired components.

The cutter assembly 51 is attached to a first end 77 of the main block52, as shown in FIG. 8. The cutter assembly 51 includes a cutting lever78 having a laterally extending cam assembly 79 attached to the upperend 80 thereof. The cutting lever 78 is attached to the main block 52 bya pivot pin 85, which passes through a bore 86 in a U-shaped cuttermounting block 87 and through a bore 82 in the lower end 81 of thecutting lever 78 such that the cutting lever 78 pivots about the pivotpin 85. Connecting devices (not shown) such as, for example, bolts orother couplers, extend through bores in the mounting block 87 and intocorresponding bores in the main block 52. A spring mechanism (not shown)is seated within the spring-receiving recess 84, at a first end andengages, at a second end, the inner face 91 of the mounting block 87.

As indicated above, the twist module 23 includes a pair of wire guides73, 74, which are attached to the main block 52 on opposite sides of thetwister pinion 54. Each of the wire guides 73, 74 includes an open lowerportion 92 that provides a passageway for wires. The twist moduleassembly 23 also includes a right-hand wire guide block 232 that has awire passageway. The right-hand wire guide block 232 is attached to thelower surface 94 of the modular housing 52 between the wire guide 73 andthe lower end 81 of the cutter lever 78. The twist module assembly 23also includes a left-hand wire guide block 231, which is attached to theleft-hand end 96 of the modular housing 52. The twist pinion 54 includesa pinion gear 99 and support sections 100,101 extending laterally awayfrom the pinion gear 99. The arcuate bushings 75, 76 engage the supportsections 100,101 and are coupled to the main block 52 by connectingdevices (not shown).

As is best seen in FIGS. 9 and 10, the knotter assembly 17 generallyincludes a drive assembly 108, which includes a hydraulic cylinder 109.A coupling block 110 is disposed around the cylinder 109. The couplingblock 110 includes a pair of cylinder pivot bearings 111,112 that extendlaterally away from the coupling block 110 and that are pivotablycoupled to a pair of corresponding cylinder mount blocks 113,114. Thecylinder mount blocks 113,114 are attached to an upper surface 115 ofthe frame cylinder mount 36. The cylinder 109 extends through an opening116 defined within the frame cylinder mount 36 such that the cylinder109 can pivot relative to the blocks 113,114 and the frame cylindermount 36. The drive assembly 108 also includes a piston rod 117 slidablydisposed partially within the cylinder 109. A clevis 118 is secured, atan upper end 119, to a lower end 120 of the piston rod 117. The clevis118 is pivotably coupled, near a lower end 121, to a gripper-releasebearing block 122 using a clevis pin 123 that passes through apertures124 on the clevis 118. A clevis pin tab 125 is secured to an outsidesurface of the gripper-release bearing block 122 for holding the clevispin 123 in place. The gripper-release bearing block 122 is fixablyattached to an upper surface of the gripper-release block 151, which isdescribed in greater detail below.

As illustrated, for example, in FIGS. 9-11, the torque tube assembly 28includes a torque tube 128 rotatably mounted within the frame assembly22. A spacer plug 43 is disposed between each end of the torque tube 128and the inside surface of the corresponding frame side 30, 31. Thespacer plugs 43 are coupled to torque tube bearings 129,130, each ofwhich extends into the respective end of the torque tube 128, supportingthe torque tube 128 such that the torque tube 128 can rotate about anaxis oriented lengthwise through the center of the torque tube 128. Inan embodiment, a total of two operating arms 131,132 are fixedlyattached to the torque tube 128 in a spaced relationship along thelength thereof. The two operating arms 131,132 are mating segment gearand ejector operators.

Two operating arms 131,132 are attached to the torque tube 128, inaccordance with embodiments of the inventions: a right-hand operatingarm 131 and a left-hand operating arm 132. As seen in FIG. 11, each ofthe operating arms 131,132 is fixably attached, at a first end thereof,to the torque tube 128 and extends away from the torque tube 128. Eachoperating arm 131,132 includes a wire ejector finger 134,135 attached ata second end and extending away therefrom in a generally perpendiculardirection such that, in operation, the ejector fingers 134, 135 passthrough the ejector slots 55 and engage the wire 19 to eject the wire 19from the knotter assembly 17.

A roller cam 142 is rotatably disposed between the second ends 136 ofthe operating arms 131, 132. A camroll shaft 138 extends through theroller cam 142 and is affixed, at each end, to an operating arm 131, 132such that the roller cam 142 rotates about the camroll shaft 138. Theroller cam 142 engages an arcuate slot 139 defined within the segmentgear 140.

As is further illustrated in FIG. 11, the right-hand operating arm 131includes a first rocker block 149 attached to the outside surface of thearm 131 and near the second end thereof. Similarly, the left-handoperating arm 132 includes a second rocker block 144 attached to theoutside surface of the arm 132 and near the second end thereof. As bestseen in FIGS. 2A, 3, and 10, the left-hand operating arm 132 includes acutter-operating cam mount 146 attached to the outside surface of thearm 132 and near the first end thereof. A cutter-operating cam 147 isrotatably mounted on a cutter-operating cam shaft 148 that extendslaterally away from the outside surface of the mount 146. Thecutter-operating cam 147 engages a cutter-operator block 220 on a firstupward-inclined surface 221 thereof. The cutter-operator block 220pivots about a bushing 222 such that a second upward-inclined surface223 engages a cutter-lever cam assembly 79 to cut the wire 19.

As is further illustrated in FIG. 11, the right-hand operating arm 132includes a gripper-release assembly 150. The gripper-release assembly150 includes a gripper-release block 151, a gripper-release bearingblock 152, and a gripper release operator 153, which is attached, at afirst end, to a forward surface of the gripper-release bearing block152. A gripper release cam 156 is rotatably mounted on a gripper releaseshaft extending from the second end of the gripper-release operator 153.

Upon extension or retraction of piston rod 117, the entire torque tubeassembly 28 is correspondingly pivoted about a rotational axis orientedlengthwise through the center of the torque tube 128. The variousoperating components carried by the operating arms 131,132 operate, on asequential basis, the various assemblies described herein for causingthe gripping, knotting, cutting and ejecting of a bale wire. Thisoperation will be described in further detail below.

The segment gear assembly 24 is best seen in FIGS. 1, 2, and 10. Thesegment gear assembly 24 includes a segment-gear bearing housing 210, asegment-gear hub 211, and a segment gear 140. The segment-gear bearinghousing 210 houses a segment gear bearing 212. The segment gear assembly24 includes a segment gear 140 having a toothed face 213 that engagesthe pinion gear 99. The segment gear 140 further includes an elongateddrive slot 139. The segment gear 140 is rotatably coupled to atransverse support shaft 160, which is rotatably coupled at each end tothe frame walls 30, 31 such that the support shaft 160 pivots inconjunction with the segment gear 140.

As is best seen in FIGS. 2A, 2B, 3, and 10, the knotter arm assembly 25includes a knotter cover 161 which is generally disposed beneath theknotter assembly 17. The knotter cover 161 includes an apertured plate162 such as is illustrated in FIG. 9. The knotter cover 161, as shown inFIG. 14, includes a pair of wire guides 73,74, a central finger 241, anda fixed gripper 240. As further illustrated in FIG. 16, when the cover161 is closed, the elements attached to the cover meet with the elementsdisposed on the twist module assembly 23 to create an overall wire path248 defined throughout the various elements. A pair of knotter-coverarms 163, 164 is fixed, at a lower end, to an upper surface of theknotter cover 161 and extends upwardly away from the knotter cover 161.At an upper end, each knotter arm 163, 164 is pivotably coupled to asegment-gear bearing housing 210, which is pivotably coupled, using apair of spacer plugs 44, 46 to a frame side 30, 31. Each knotter arm163, 164 has a knotter-arm cam side plate 169, 170 fixably attached toan inside surface 171, 172 of the corresponding knotter arm 163, 164. Aprotrusion 173, 174 extends laterally away from the rear surface of eachknotter arm 163, 164. An operator bearing 177, 178 is disposed betweenknotter-arm cam side plate 169, 170 and the protrusion 173, 174 on eachknotter arm 163, 164 and is rotatably coupled therein by way of anoperator bearing shaft 181, 182.

The left-hand knotter arm 163 includes a ratchet assembly 26 thatfacilitates opening the knotter cover 161 and locking the knotter cover161 in an open position such as the position illustrated in FIG. 19 forservicing. Additionally, as illustrated in FIG. 2B, a bias spring 260biases the cover 161 toward a closed position. As shown, the bias spring260 extends between a spring connector 261 that extends laterally awayfrom a mount block 262 disposed on the outside surface of the left-handknotter arm 163 and a stud 263 that is attached to the outside surfaceof the left-hand frame side wall 31.

As is best seen in FIGS. 17-19, the ratchet assembly 26 includes aratchet gear 183 having one or more teeth 250 (e.g., two teeth), aratchet latch mounting block 184, and a ratchet gear lever 185 having anengagement portion 251. The number of teeth 250 included on the ratchetgear 183 will depend upon the desired number of open positionsassociated with the knotter cover 161. In an embodiment, the ratchetgear 183 includes two teeth, thereby allowing for two different openpositions.

As is best seen in FIG. 18, lever 185 includes a spring recess 252 thatreceives a spring (not shown, as these are well-known in the art) thatextends between the top of the lever 185 and a recess 253 disposed inthe underside of the ratchet latch mounting block. The spring causes adownward force on the lever 185, causing the engagement portion 251 ofthe lever 185 to act as a pawl that engages the teeth 250 on the ratchetgear 183. Thus, in embodiments and as depicted in FIG. 19, a user canlift the knotter cover 161 to a first or second open position. Theoperation described above of the ratchet assembly 26 locks the cover 161in the selected position. In this manner, the user can service parts ofthe knotter assembly 17 such as, for example, by removing the twistmodule assembly 23 from the frame assembly 22 and replacing it withanother twist module assembly 23 having new or repaired parts or partsdesigned for tieing wire of a different gauge.

The gripper assembly 27 is illustrated in FIGS. 9, 12, and 13. Thegripper assembly 27 includes a connector 186. The connector 186 includesan upright plate 187. An upper aperture tab 188 and an opposed loweraperture tab 189 extend laterally away from the upright plate 187. Astop block 190 is fixably attached to the lower aperture tab 189. Theupright plate 187 further includes a pair of spring recesses thatreceive a pair of coil springs, both of which are well-known in theprior art and, therefore, are not illustrated herein. The plate 187 isattached to the outside surface of frame side wall 31.

The gripper assembly 27 also includes a generally dogleg-shaped,wire-engaging member 193. The wire-engaging member 193 includes awire-engaging end 194 and an actuator end 195. The wire-engaging member193 is pivotably attached to a pivotal block 196 that is pivotablyattached to the connector 186 by way of a pair of connection pins197,198. An operator segment 199 is secured to an outside surface of theblock 193 and includes an inclined operating surface 200. The pivotalblock 196 houses a spring assembly (not shown), as is known in the art.Additionally, those having skill in the art will appreciate that abiasing spring (not shown) may extend between the block 196 and thewire-engaging member 193 and that coil springs (not shown) may extendbetween the plate 187 and the block 196.

A sensor mounting block 191 is attached to an outside surface of theupright plate 187 and is configured for housing a sensor (not shown)that detects when the actuator end 195 of the wire-engaging member 193moves to a position near the sensor due to the wire being in a grippableposition so that the system can begin the process of reversing the feeddirection of the wire to tension it, as is known in the prior art.Additionally, those having skill in the art will recognize that anextendable cylinder (not shown) may be attached to the outside of theupright plate 187 and aligned such that, when the cylinder is extended,the cylinder engages the actuator end 195 of the wire-engaging member193 and pushes the actuator member 195 away from the cylinder, therebycausing the wire-engaging member 193 to pivot in a counter-clockwisedirection, gripping the wire.

An exemplary operation of baler 10 is described below. Initially, thewire 19 is manually fed through guides (not shown), and jogged aroundthe bale via the track 18 using the pinch-roll mechanism 16 to slowlyadvance the wire 19, and into the gripper assembly 27, which grips thewire 19, to a “home” position such that the sensor associated with thegripper (discussed above, but not illustrated as it is well-known in theprior art) activates. Activation of the sensor communicates to the baleror an operator that the system 15 is ready to tie a bale. When a bale isproperly positioned relative to the outlet 14 such that the wire-tieingsystem 15 is aligned with a first wire-tie position associated with thebale, the system 15 receives a manual or electronic input to initiatetieing. Upon receiving an input from the baler or operator, the gripperassembly's 27 grip on the wire 19 is tightened, the wire 19 is tensionedaround the bale by a reverse action of the pinch-roller mechanism 16that feeds wire into an accumulation area (not shown, as it is taught inthe prior art) inside the feed and tensioning structure 21, and a twistknot is completed. Upon ejection, the wire 19 is automatically re-fedthrough the guides and track 18 to the gripped home position, activatingthe sensor to indicate that the system 15 is ready to tie. The operatoror the baling machine 10 indexes the bale to a second (e.g., next)wire-tie location. As the system repeats itself from a ready status, asensor (not shown) associated with the outlet 14 sends an initiationsignal to wire-tieing system 15.

To prepare a wire 19 such that the system is in a home position, thepinch-roll mechanism 16 is actuated via a drive motor (not shown) toadvance the wire 19, drawing wire 19 from the spool 20. The pinch-rollmechanism 16 advances the wire 19 through the knotter assembly 17, andaround the guide track 18 until the leading end of the wire 19 passesunderneath the wire 19 section already disposed within the knotterassembly 17.

The pinch-roll mechanism 16 continues advancing the wire 19 until theleading edge thereof passes and engages the wire-engaging end 194 of thewire-engaging member 193 of the gripper assembly 27. As a result, thewire-engaging member 193 slightly pivots in a clockwise direction. Thewire-engaging end 194 engages the wire 19 and the actuator end 195 islocated beneath the sensor (not shown). The sensor detects the presenceof the actuator end 195 and causes a signal to be sent to the pinch-rollmechanism 16 to stop advancing the wire 19. The system 15 and wire 19are now in a home, or ready, position.

Upon receiving a signal to tie, the pinch-roll mechanism 16 begins toreverse the advancement of the wire 19. This reverse advancementtensions the wire 19 around the track 18. As a result of its engagementwith the wire 19, the wire-engaging member 193 pivots in acounter-clockwise direction until the wire-engaging member 193encounters stop block 190. The pinch-roll mechanism 16 continues thereverse advancement of the wire 19 to tighten the gripping engagementthat the wire-engaging end 194 of the wire-engaging member 193 has withthe wire 19. To ensure that the wire is gripped tightly enough forcutting, a cylinder (not shown) may be actuated, which engages theactuator end 195 of the wire-engaging member 193 and causes furthercounter-clockwise pivoting of the wire-engaging member 193.

The drive assembly 108 is actuated to twist-knot the wire 19, to cut thewire 19, and to eject the knotted wire from the knotter assembly 17. Inembodiments, the cylinder 109 and piston rod 117 mechanism is actuated,thereby causing the cylinder 109 to pivot relative to the mountingblocks 113, 114 and the frame cylinder mount 36. As a result, the clevis118 causes the gripper-release bearing block 122 and gripper releaseblock 151 to rotate, thereby rotating the torque tube assembly 28. Inresponse to this rotation, the roller cam 137 rides within the driveslot 139, causing the segment gear 140 to pivot, thereby causingrotation of the pinion gear 99. The rotation of the pinion gear 99causes the two portions of the wire 19 to be twisted together. Inembodiments, for example, the portions of the wire 19 are twistedthrough four turns, while in other embodiments, the portions are twistedthrough three and one-quarter turns or some other number of turns.

After the wire 19 is twisted, the cutter lever 78 is actuated byengagement of block 220 with the cam 79 secured to the upper end 80 ofthe cutter lever 78, causing the cutter lever 78 to rock about the pivotpin 85, shearing the wire 19.

Next, the gripper release block 151 is pivoted to cause its engagementwith the operating surface 200 of the operator segment 199. As a resultof this engagement, the pivotal block 196 is pivoted over center,releasing the wire 19 from the wire-engaging member 193. The knottercover 161 is moved slightly upwardly to allow ejection of the wire 19.As illustrated in FIGS. 14-16, the slight upward movement of the knottercover 161 is occurs as a result of the interaction of the rocker blocks142,144 carried by the operating arms 131,132 with the operator bearings177,178 carried by the knotter-cover arms 163,164. Additionally, theejector fingers 134,135 pass through the slots 55 to engage and ejectthe wire 19.

The device 10 is then returned to a ready position by actuation of thecylinder 109 and piston rod 117 mechanism to retract the piston rod 117within the cylinder 109. As a result, the segment gear 140 and thecomponents of the torque tube assembly 28 return to their originalpositions. The knotter cover 161 returns to its original position underthe influence of gravity and additional assistance from the bias spring260, which biases the cover 161 inwardly toward the frame assembly 22.The gripper assembly 27 also returns to its original position.

According to embodiments of the invention, the knotter cover 161 can bereadily shifted to allow removal of the twist module assembly 23. Inembodiments, a user lifts up on the knotter cover 161 through an arc ofabout sixty degrees. In some embodiments, the arc may include less thansixty degrees, while in other embodiments, the arc may include more thansixty degrees. The ratchet assembly 26 causes the knotter cover 161 tolock in place at one or more open positions. To lower the cover, theratchet gear lever 185 is depressed to release the pawl on 185 from theratchet gear 183 and the cover is lowered.

Moreover, because the twist module assembly 23 is removably coupled tothe frame assembly 22, it is relatively simple to remove the connectors67,68 and slide the twist module assembly 23 off of the frame assembly22. Once the twist module assembly 23 is removed, a new twist moduleassembly 23 (or, e.g., a twist module assembly with previously repairedparts) can be installed onto the frame assembly 22. In this manner,components of the twist module assembly 23 can be rapidly replaced whenthey wear, while minimizing machine 10 down-time. Additionally, thismodular operation allows for rapidly switching the gauge of wire that isbeing used for baling.

The present invention has been described in relation to particularembodiments, which are intended in all respects to be illustrativerather than restrictive. Alternative embodiments will become apparent tothose of ordinary skill in the art to which the present inventionpertains without departing from its scope.

From the foregoing, it will be seen that this invention is one welladapted to attain all the ends and objects set forth above, togetherwith other advantages which are obvious and inherent to the system andmethod. It will be understood that certain features and subcombinationsare of utility and may be employed without reference to other featuresand subcombinations. This is contemplated by and is within the scope ofthe claims.

What is claimed is:
 1. A method for removing and reinserting atwist-module sub-assembly in a knotter assembly on a material balingapparatus, the twist-module sub-assembly accessible from a first side ofthe knotter assembly, the method comprising: rotating a knotter coverarm assembly of the knotter assembly outwardly from the first side ofthe knotter assembly; securing the knotter cover arm assembly in araised rotated position; accessing, through the first side of theknotter assembly, one or more coupling devices securing the twist-modulesub-assembly to the knotter assembly; removing the one or more couplingdevices; and extracting the twist-module sub-assembly as a unit from theknotter assembly substantially via the first side of the knotterassembly, wherein upon extraction of the twist-module sub-assembly as aunit from the knotter assembly substantially via the first side of theknotter assembly, the knotter assembly is configured to receive thetwist-module sub-assembly reinserted into the knotter assemblysubstantially via the first side of the knotter assembly.
 2. The methodof claim 1, further comprising: reinserting the twist-modulesub-assembly into the knotter assembly substantially via the first sideof the knotter assembly; installing the one or more coupling devices;releasing the knotter cover arm assembly from the raised rotatedposition; and rotating the knotter cover arm downwardly to asubstantially vertical original position.
 3. The method of claim 2,wherein the reinserted twist-module sub-assembly is configured foroperation of the knotter assembly using a different gauge of wire thanthe previous twist-module sub-assembly insertion.
 4. The method of claim2, wherein the reinserted twist-module sub-assembly includes one or morenew or remanufactured wear components.
 5. The method of claim 1, whereinthe knotter assembly includes a ratchet assembly configured to lock theknotter cover arm assembly in the raised rotated position, and whereinsecuring the knotter cover arm assembly in a raised rotated positionfurther comprises: engaging a ratchet gear associated with the knottercover arm assembly with a pawl associated with the frame assembly. 6.The method of claim 1, wherein the raised rotated position isapproximately 60 degrees from vertical.
 7. The method of claim 1,wherein extracting the twist-module sub-assembly from the knotterassembly substantially via the first side of the knotter assemblycomprises sliding the twist-module sub-assembly along one or more guiderails associated with the frame assembly.
 8. A method for replacing atwist-module sub-assembly, as a unit, from a knotter assembly on amaterial baling apparatus, the method comprising: accessing a firsttwist-module sub-assembly from a first side of the knotter assembly,said knotter assembly comprising a knotter cover arm assembly pivotablycoupled to the knotter assembly, said knotter cover arm assembly havinga knotter cover, wherein accessing the first twist-module sub-assemblycomprises: (1) rotating at least a portion of the knotter cover armassembly outwardly from the first side of the knotter assembly from anoriginal position to a raised position relative to the knotter assembly,wherein rotation of at least a portion of the knotter cover arm assemblycauses rotation of the knotter cover away from the knotter assemblyfirst side; (2) securing the at least a portion of the knotter cover armassembly in the raised position relative to the knotter assembly; and(3) removing, through the first side of the knotter assembly, one ormore coupling devices securing the first twist-module sub-assembly tothe knotter assembly; and extracting the first twist-module sub-assemblyas a unit from the knotter assembly substantially via the first side ofthe knotter assembly, wherein upon extracting the first twist-modulesub-assembly from the knotter assembly, the knotter assembly isconfigured to receive a second twist-module sub-assembly via the firstside of the knotter assembly.
 9. The method of claim 8, furthercomprising: inserting the second twist-module sub-assembly into theknotter assembly; installing the one or more coupling devices; releasingthe at least a portion of the knotter cover arm assembly from the raisedposition; and rotating the at least a portion of the knotter cover armassembly downwardly to the original position, wherein the secondtwist-module sub-assembly is inserted into the knotter assemblysubstantially via the front of the knotter assembly.
 10. The method ofclaim 9, wherein the second twist-module sub-assembly is configured foroperation of the knotter assembly using a different gauge of wire thanthe first twist-module sub-assembly.
 11. The method of claim 10, whereina user time required for replacing the first twist-module sub-assemblywith the second twist-module sub-assembly for operation of the knotterassembly using a different gauge of wire is shorter than a user timerequired for replacing one or more gauge-specific components in thefirst twist-module sub-assembly and reinstalling the first twist-modulesub-assembly.
 12. The method of claim 9, wherein the second twist-modulesub-assembly includes one or more new or remanufactured wear components.13. The method of claim 9, wherein a user time required for replacingthe first twist-module sub-assembly with the second twist-modulesub-assembly is shorter than a user time required for replacing one ormore wear components in the first twist-module sub-assembly andreinstalling the first twist-module sub-assembly.
 14. The method ofclaim 8, wherein the knotter assembly includes a ratchet assemblyconfigured to lock the knotter cover arm assembly in the raisedposition, and wherein securing the knotter cover arm assembly in araised position further comprises: engaging a ratchet gear associatedwith the knotter cover arm assembly with a pawl associated with theknotter assembly.
 15. The method of claim 8, wherein the raised positionis approximately 60 degrees from vertical.
 16. The method of claim 8,wherein extracting the first twist-module sub-assembly from the knotterassembly substantially via the front of the knotter assembly comprisessliding the first twist-module sub-assembly along one or more guiderails associated with the knotter assembly.
 17. A knotter assembly for amaterial baling apparatus, wherein the knotter assembly comprises: aframe having a base plate and a pair of parallel opposed side walls; areplaceable first twist-module sub-assembly removably coupled to theknotter assembly; and a knotter cover arm assembly comprising a pair ofopposed knotter cover arms coupled, at a first end of each arm, to aknotter cover, and pivotably coupled, at a second end of each arm, to ashaft such that rotation of the arms about the shaft causes the knottercover to at least partially extend from a first side of the knotterassembly to provide access to the replaceable first twist-modulesub-assembly, wherein a method for replacing the first twist-modulesub-assembly comprises: (1) rotating the first end of the knotter coverarms outwardly from the first side of the knotter assembly; (2) securingthe knotter cover in a raised rotated position using a ratchet assemblycoupled to the knotter assembly; (3) accessing, through the first sideof the knotter assembly, one or more coupling devices securing the firsttwist-module sub-assembly to the knotter assembly; (4) removing the oneor more coupling devices; (5) extracting the first twist-modulesub-assembly as a unit from the knotter assembly substantially via thefirst side of the knotter assembly; and (6) replacing the firsttwist-module sub-assembly with a second twist-module sub-assembly,wherein upon extraction of the first twist-module sub-assembly as a unitfrom the knotter assembly substantially via the first side of theknotter assembly, the knotter assembly is configured to receive thesecond twist-module sub-assembly.
 18. The knotter assembly of claim 17,wherein securing the knotter cover in a raised rotated positioncomprises engaging a ratchet gear associated with the knotter cover armassembly with a pawl associated with the frame.
 19. The knotter assemblyof claim 17, wherein the second twist-module sub-assembly replaced intothe knotter assembly comprises one or more of the following: the firsttwist-module sub-assembly having one or more replaced wear components;the first twist-module sub-assembly having one or more replacedgauge-specific components; a second twist-module sub-assembly having oneor more gauge-specific components that are different than one or moregauge-specific components of the first twist-module sub-assembly; and asecond twist-module sub-assembly having one or more new componentsdifferent than one or more parts of the first twist-module sub-assembly.20. The knotter assembly of claim 19, further comprising: replacing theone or more coupling devices; releasing the knotter cover from theraised rotated position; and rotating the knotter cover downwardly to asubstantially vertical original position.